Pile fabric and method of weaving the same.



M. J. WHITTALL.

PILE FABRIC AND METHOD OF WEAVING THE SAME.

APPLICATION FILED IAN. 26,-1903.

948,384. Patented Feb. 8, 1910.

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M. J. WHITTALL. PILE FABRIC AND METHOD OF WEAVING THE SAME.

APPLIGATION FILED JAN. 26, 1903.

Patented Feb. 8, 1910.

2 SHBETS-SHEET 2.

000000 000 00 0000 000000000 oooooooooooooo 0000 o 0 oo 0 00006000000000 00 000 000 000 000 00000000 0 o o o o o o o 0 MW o o o o f o w /m m 1 0 MATTHEW J. WHI'ITALL, OF WORCESTER, MASSACHUSETTS.

PILE FABRIC AND METHOD OF WEAVING THE SAME.

Specification of Letters Patent.

Application filed January 26, 1903.

Patented Feb. 8, 1910.

Serial No. 140,478. (Specimens) To all whom it may concern:

Be it known that I, MATTHEW J. WHIT- TALL, a citizen of the United States, residing at IVorcester, in the county of Worcester and State of Massachusetts, have invented a new and useful Pile Fabric and Method of Veaving the Same, of which the following is a specification.

This invention relates to that class of pile fabrics in which substantially the same pattern is reproduced at the back of the fabric as is shown in the face thereof.

The especial objects of this invention are to provide a pile fabric which is especially adapted for carpeting employed as rugs or floor-coverings where the backs are liable to be exposed; and to provide a method of weaving this fabric upon an ordinary carpet loom without essentially changing the loom or adding operative parts thereto.

In the accompanying two sheets of drawings, Figure 1 is a fragmentary View of a series of complementary jacquard cards secured together to form a portion of a chain for weaving a fabric according to this invention. Fig. 2 is an enlarged diagrammatic view illustrating the relation of the figuring warp threads and of the weft threads. Fig. 3 is a similar View, the location of the chain warp threads being indicated'in dotted lines. Fig. 4 is a fragmentary view of one of the jacquard cards for selecting the desired ones of the figuring warps to form a pile. Fig. 5 is a diagrammatic view showing the position of the shedding mechanism during that beat of the loom corresponding in time with the action of the card shown in Fig. ft- Fig. 6 is a diagrammatic view illustrating the threads woven into the fabric during the beat of the 100111 illustrated in Fig. 5. Fig. 7 is a diagrammatic view illustrating the position of the shedding mechanism during the second beat of the loom. Fig. 8 is a diagrammatic view of the figuring threads woven into the fabric during the beats of the loom illustrated in Figs. 5 and 7. Fig. 9 is a fragmentary view of the card complementary to that illustrated in Fig. 4:. Fig. 10 is a diagrammatic view illustrating the position of the shedding mechanism during the third beat in the cycle of operation. Fig. 11 is a diagrammatic view of the threads woven into the fabric during the first three beats in the cycle of operation. Fig. 12 is a diagrammatic view illustrating the position ofthe shedding mechanism durdifferently colored figuring warps. In this class of fabrics attractive and widely varied designs may be shown on the face of the fabric, but the backs of this class of fabrics have ordinarily been left entirely plain, or have had simply such accidental variations as have resulted from the indiscriminate showing of the bunches of variously colored figuring warps. That is to say, at the back of ordinary Wilton and Brussels carpets, in addition to the cotton chain warps and the filling threads, the figuring warps may be shown, but they will not appear in any particular sequence. It results from' this that the backs of Wilton and Brussels carpets are extremely unattractive, and in weaving carpets which are identical in design and coloring upon the face of the car pets, there is no certainty that different pieces will have identical appearance on their backs. Furthermore, in manufacturing carpets or other fabrics of this class, it is desirable that the piles should be tied or locked in place as firmly as possible, the life of fabrics of this class depending to a considerable extent upon the secureness with which the surface threads are tied into the chain or body of the fabric.

The especial object of the present invention is to provide a three-shot pile fabric of the class referred to, in which the pattern will be reproduced or made to appear at the back of the fabric, and to provide an efficient method of weaving said fabric upon an ordinary carpet loom without substantially altering the loom, and without adding operative parts thereto. To accomplish these objects in weaving carpeting or other fabrics according to my invention, I employ a set of cards containing twice as many cards as would be required to weave the same pattern into ordinary WVilton or Brussels carpets. The successive cards of the set employed are complementary in character. That is to say, one of such pair of cards will call up certain ones of the figuring warpthreads, while the other .card will call up all of the other figuring warps which were not called up by the first card, so that each one of the figuring warps will be lifted up above the upper shed or into the pile forming leash once either in the operation corresponding to the first card or in that corresponding to the second card. A pile Wire is inserted and a pile is formed only at each alternate one of these selecting operations, the other selecting operation serving simply to lift the remainder of the figuring warps away from the back of the fabric, so that the figuring warps which have appeared in the face of the fabric will then be carried through and appear at the back of the fabric, and although this second selecting operation carries the remainder of the threads up above the upper shed and into the pile forming leash no pile wire will be inserted at this time, and said threads will not be shown on the face of the carpet.

In operating a loom according to my invention, the figuring warps are controlled entirely by the jacquard mechanism or other selecting mechanism of the loom, and the comber-board, or lifter-board so called, which is employed in weaving ordinary "Wilton and Brussels carpets may be thrown entirely out of operation, or will serve simply as a guide for keeping the lingoes for the several threads separated.

Referring to the drawings by reference letter for a detail description of a fabric constructed according to this invention, and the method of weaving the same; Fig. 1 illustrates portions of three successive sets of complementary cards; the card A, for example, being cut or perforated to control a jacquard mechanism to select the desired figuring warp threads to form one pile on the face of the fabric; the card B being cut or perforated to control a acquard mechanism to select the figuring warp threads required for a second pile on the face of the fabric; the card C being cut or perforated to con trol a jacquard mechanism to select the figuring warp threads required for athird pile on the face of the fabric; and the cards A, B and G being cut or perforated to correspond with all the threads not selected by the cards A, B and C, respectively.

Considering now the successive steps in weaving a carpet according to my invention, and as illustrated most clearly in the second sheet of drawings, Fig. shows the position of the shedding mechanism corresponding for example with a primary card A, That is to say, as shown in Fig. 5, F designates the figuring warps which are controlled by weighted strings or lingoes I from any ordinary jacquard or other selecting mechanism, one of the figuring warps F being shown lifted to appear in the face of the carpet. Running with the figuring warps F are the chain warps G and H, which are controlled by harness frames J. The threads are arranged in three distinct tiers or layers forming an upper shed 10 to receive the pile wires, and a lower shed 11 for the shuttle.

When the parts are in the position illustrated in Fig. 5, that is to say, when one of the primary cards has selected and caused the jacquard mechanism to call up certain threads which are to appear in the face of the fabric, a pile wire V is inserted, as shown in Fig. 6. At the next beat of the loom all the figuring warps occupy their normal or lowest position, and the shuttle is thrown across, or a pick is made, laying a weft thread over the figuring warps, as illustrated at M in Fig. 8. At the next beat of the loom a secondary card A, or a card which is complementary to the card A, controls the jacquard mechanism to raise all the figuring warps F, except the previously selected figuring warps, into the upper shed, and although this again opens the pile wire shed as illustrated in Fig. 10, no pile wire is inserted at this beat of the loom, although the shuttle is again thrown across, weaving in a second weft thread M, as shown in Fig. 11. At the next beat of the 100111, the chain is shifted, and the figuring warps are all allowed to resume their normal position in the lower shed, and a third weft thread is laid in place, as illustrated in Fig. 13. During these operations it will be seen that none of the figuring warps F ever occupy an intermediate or central position, this being given up solely to whichever chain-warp happens to be lifted. I regard this a feature of advantage, as the worsted or high 7 grade figuring warps will be maintained at all times as near the surface of the fabric as possible.

A diagrammatic view of the completed fabric is illustrated in Fig. 3. As shown in this figure, after the formation of each pile the thread or figuring warp appearing in that pile will then be carried through to the back of the fabric being exposed, as at 12, in connection with one of the chain warps. That is to say, in a fabric constructed according to my invention, the pattern on the face of the fabric will be substantially reproduced at the back thereof, producing a high grade of fabric in which the piles will be more firmly tied in place than usual, and which will closely simulate the appearance of hand-made Axminster carpet.

The especial advantage of the method of weaving carpeting which I have herein described, resides particularly in the fact, that the method is carried out by the ordinary carpet loom without change therein or the addition of working parts thereto. This is not only a desirable result in itself, but is one which will facilitate the production of a variety of products; for example, when it is desired to produce the same design not only in a high grade carpeting of the character herein referred to, but when it is also desired to produce said design in ordinary Wilton or Brussels carpeting the same loom may be employed for producing both fabrics without requiring any fresh drawing in or change of the warps, it simply being necessary to substitute a single set of cards instead of the set of complementary cards, and to operate the comber-board and other devices by their usual connections.

I am aware that changes may be made in practicing my invention by those who are skilled in the art without departing from the scope thereof as expressed in the claims. I do not wish, therefore, to be limited to the construction I have herein shown and described, but

l/Vhat I do claim and desire to secure by Letters Patent of the United States is l. The method of weaving pile fabrics which consists in raising the desired figuring warps to form a pile, thereafter raising all the rest of the figuring warps above the pile-forming shed but without forming a pile therefrom and weaving in the weft at each beat when a pile is not formed, whereby substantially the same pattern will be shown both upon the face and back of the fabric.

2. The method of weaving pile fabrics which consists in raising the desired figuring warps to form a pile, and thereafter raising all the rest of the figuring warps above the pile forming shed, but without forming a pile therefrom, weaving in weft threads or strands at each beat when a pile is not formed, and in binding the fabric together by chain warps, whereby substantially the same pattern will be shown upon both the face and back of the fabric.

3. The method of weaving pile fabrics, which consists in raising the desired figuring warps to form a pile and thereafter raising all the rest of the figuring warps above the pile forming shed without forming a pile therefrom, in weaving in a weft thread at each beat of the loom except during the formation of a pile, and in binding the fabric together by a binding chain, whereby substantially the same pattern will be shown both upon the face and back of the fabric.

4. The method of weaving pile fabrics which consists in raising the desired figuring warps on alternate picks, forming a pile therefrom, raising all the rest of the figuring warps above the pile forming shed on each intermediate pick, but without forming a pile therefrom, and weaving in the weft at each beat when a pile is not formed.

5. The method of weaving fabrics, which consists of raising the desired figuring warps to one side of the fabric and on the next beat carrying the same figuring warps through to the back of the fabric, simultaneously raising all the rest of the figuring warps to the first mentioned side of the fabric and weaving in a weft thread at each beat except during the formation of a pile.

6. The method of weaving pile fabrics, which consists in raising the desired figuring warps above the upper shed or into the pile-forming leash to form a pile, then carrying the same figuring warps through to the back of the fabric and simultaneously raising all the rest of the figuring warps above the pile-forming shed without forming a pile therefrom, weaving a weft thread at each beat except during the formation of a pile, binding the fabric together by a binding chain, the warp of said chain occupying an intermediate or central position between the figuring warps, and retaining the figuring warps at all times near the surfaces of the fabric and on the outside of said chain warps.

7. As an article of manufacture, a three shot pile fabric having a stufi'er warp with a plurality of wefts above and one below, each round of weft shots being included in one shed, and a plurality of binding chain warps and figuring warps lying embedded between the two rounds of weft and associated with the stuffer warp, excepting when called to the surface, the threads called to the surface dropping to the back of the fabric around the lower weft and up among the upper wefts of the set and appearing upon the face of the fabric as a pile tuft and then disappearing at the same point at the bottom of the fabric.

8. As an article of manufacture, a three shot pile fabric having a number of figuring 105 warps, binding chain warps and filling threads, the desired figuring warps for forming a pile extending above the face of the fabric, and all the rest of the figuring warps extending above the upper chain warps and 110 lying on top thereof, in alternate rows between the rows forming the pile, whereby substantially the same pattern is shown both upon the face and back of the fabric, and none of the figuring warps run with the up- 115 per leash of the chain-warps.

9. As an article of manufacture, a pile fabric having figuring warps, binding chain warps, and filling threads, and having a pile, all of the figuring warps not contained in 120 the pile at any pick extending through to the other side of the fabric but lying in contact with the weft.

In testimony whereof I have hereunto set my hand, in the presence of two subscribing 125 witnesses.

MATTHEWV J. VVHITTALL. Witnesses:

J. ELMER HALL, PHILIP l/V. SOUTHGATE. 

